Vacuum pump/ air and gas compressor

ABSTRACT

A pump housing for a pump/compressor includes a front portion and a back portion. The front portion includes an opening forming a motor bearing pocket for seating a motor bearing and through which a motor shaft extends towards the back portion, at least one vent hole radially outwardly spaced from the opening for cooling, and a protrusion extending outward from the front portion, wherein the protrusion is configured to locate a motor housing. A pump/compressor includes the described pump housing and a motor. The front portion of the pump housing is configured as a motor endbell, such that the motor does not include a separate front endbell. The pump/compressor further may include a piston assembly having an integral piston and connecting rod member operable within the pump/compressor. Exhaust air is directed through valve porting in the piston and out of a bottom of the connecting rod.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/764,773 filed Feb. 14, 2013, which is hereby incorporated herein by reference.

FIELD OF INVENTION

The present invention relates generally to pumps/compressors, and more particularly to vacuum pumps/air and gas compressors.

BACKGROUND

Compact pumps and compressors, including vacuum pumps and air and gas compressors, are utilized in a variety of applications. In medical applications in particular, such pumps and compressors may be used in oxygen concentrator systems that supply oxygen to users as a medical replacement for an oxygen tank.

As such, it is important for pumps and compressors in oxygen concentrators and similar devices to be compact for user portability and discreetness of operation. It is also important for pumps and compressors to be essentially noiseless, and to have efficient air flow through the pump/compressor. It is also important for the pump to incorporate an efficient cooling mechanism. Configurations of conventional pumps and compressors, however, have proven to be deficient in these aspects, and also tend to be overly complex with numerous components that need to be separately manufactured and assembled.

SUMMARY OF INVENTION

A need exists in the art for an improved pump/compressor that overcomes the above deficiencies of conventional configurations. The pump/compressor utilizes integral components by which a housing is configured for positioning a motor without the need for a separate motor endbell. This configuration provides enhanced portability and ease of manufacturing, with enhanced discreet operation and superior cooling performance.

An aspect of the invention is a pump housing for a pump/compressor. In exemplary embodiments, the pump housing includes a front portion and a back portion. The front portion of the pump housing includes an opening forming a motor bearing pocket for seating a motor bearing and through which a motor shaft extends towards the back portion, at least one vent radially outwardly spaced from the opening for cooling, and a protrusion extending outward from the front portion, wherein the protrusion is configured to locate a motor housing. The protrusion may be a circular protrusion with multiple vent holes that are circumferentially spaced about the opening.

Another aspect of the invention is a pump/compressor including the described pump housing and a motor. The front portion of the pump housing is configured as a motor endbell, such that the motor does not include a separate front endbell. The pump/compressor further may include a pump housing cover having an integral gasket over molded onto a cover portion of the pump housing cover. The pump/compressor further may include a piston assembly having an integral piston and connecting rod member operable within the pump/compressor. The piston assembly may include a piston cup held against the piston by a retainer washer, wherein exhaust air from a top of the washer is directed through valve porting in the piston and out of a bottom of the connecting rod. The pump/compressor further may include first and second cylinders and heads respectively coupled to a top and bottom portion of the pump housing, and first and second integral pumping chambers and heads respectively coupled to the first and second cylinders.

These and further features of the present invention will be apparent with reference to the following description and attached drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. Rather, the invention includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto. Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram depicting a perspective view of an exemplary pump/compressor in accordance with embodiments of the present invention.

FIG. 2 is a schematic diagram depicting a perspective view of an exemplary pump housing and motor assembly for use in the pump/compressor of FIG. 1.

FIG. 3 is a schematic diagram depicting a perspective view principally of the exemplary pump housing from the assembly of FIG. 2.

FIG. 4 is an exploded cross-sectional view of an exemplary pump housing and motor assembly comparable to the assembly of FIG. 2.

FIG. 5 is a schematic diagram depicting a perspective view of an exemplary piston assembly, including an integral piston and connecting rod with a two port valve.

FIG. 6 is a schematic diagram depicting a perspective view of an exemplary pump housing cover with an over molded gasket.

FIG. 7 is a schematic diagram depicting an exploded view of an integral pumping chamber and head with fastened reed valves, gasket and cover plate.

DETAILED DESCRIPTION

Embodiments of the present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It will be understood that the figures are not necessarily to scale.

FIG. 1 is a schematic diagram depicting a perspective view of an exemplary pump/compressor 10 in accordance with embodiments of the present invention.

The pump/compressor 10 includes a pump housing 12 and a motor 14 coupled to the pump housing. The pump housing includes a front portion 16 and a back portion 18. A motor shaft 20 of the motor is configured to extend through the pump housing from the front portion 16 to the back portion 18, as shown in FIG. 1.

The pump housing 12 includes an opening 30, which is configured as a motor bearing pocket for seating a motor bearing 32 and serves as the motor endbell. In the depiction of FIG. 1, the motor is positioned in part within the opening 30 forming the motor bearing pocket, and the opening or motor bearing pocket 30 and motor bearing 32 provide a support structure for the motor 14 about the motor shaft 20. In particular, the shaft of the motor is configured to extend through the opening 30 and bearing 32 so as to extend from the front portion 16 of the housing to the back portion 18. The integral motor bearing pocket results in the front portion of the pump housing being configured as a motor endbell, which allows for the elimination of a separate front motor endbell thereby reducing complexity and cost. The motor housing and the pump housing, therefore, are integral such that the motor housing does not exist as a discrete unit apart from the assembly with the pump housing.

The pump housing 12 also includes at least one vent hole 34 (four vent holes are present in this exemplary embodiment) that are radially outwardly spaced from the motor bearing pocket 30 for cooling. In the illustrated embodiment, the four vent holes 34 are circumferentially spaced about the motor bearing pocket 30. The vent holes in the pump housing about the motor bearing pocket provide enhanced cooling and weight savings as compared to conventional configurations. The absence of a front motor endbell on the front end of the shaft 20 permits ventilation to the internal motor components by providing the vent holes in the pump housing. The vent holes also reduce material usage and reduce product weight.

The pump/compressor 10 also includes a first cylinder and head 40 coupled to a top 42 of the pump housing 12. The first cylinder 40 further is coupled to an integral first pumping chamber and head 44. A second set of comparable components is provided oppositely at the bottom end of the pump housing. In particular, a second cylinder and head 46 is coupled to a bottom 48 of the pump housing 12. The second cylinder 46 further is coupled to a second integral pumping chamber and head 50. Lead wires 52 are provided that couple the motor to a suitable controller, such as an external driver or integrated electronics.

FIG. 2 is a schematic diagram depicting a perspective view of a portion of the pump/compressor of FIG. 1, specifically including a pump housing and motor assembly 60. FIG. 3 is a schematic diagram depicting a perspective view principally of the pump housing 12 extracted from FIG. 2. Accordingly, like components are provided with the same reference numerals in FIGS. 2 and 3 as in FIG. 1. The pump housing and motor assembly 60 includes the pump housing 12 and the motor 14 configured as described above.

As seen particularly in FIGS. 2 and 3, the pump housing 12 includes a protrusion 62 extending outward from the front portion 16 of the housing 12. The protrusion is configured to locate a motor housing 64 of the motor. The result is that the pump housing and motor housing form an integral assembly. The pump housing and integral motor housing eliminate the need for a separate front motor endbell or a separate motor housing. In an exemplary embodiment, the protrusion 62 is a circular protrusion. Additionally, the motor bearing pocket 30 and the at least one vent hole 34 (again, four vent hoses are in this embodiment) are provided in the protrusion 62. Because there is no motor endbell on the shaft end of the motor, the motor housing is located using the described features on the pump housing. In this manner, the inner diameter of the motor housing is located by the circular protrusion on the pump housing.

As seen in FIGS. 2 and 3, the pump housing has a first end portion 66, a second end portion 68, and a central portion 70 configured between the first and second end portions. The portions of the housing are shaped and configured to accommodate the integral connection with the motor housing 64. FIGS. 2 and 3 also identify the top 42 and bottom 48 of the motor housing, as to which the cylinders 40 and 46 respectively are coupled. In addition, the motor 14 is provided with a rear motor endbell 72 secured with a plurality of fasteners 74 (see specifically FIG. 2).

FIG. 4 is an exploded cross-sectional view of the exemplary pump housing and motor assembly 60 comparable to that depicted in FIG. 2. Accordingly, like components are provided with the same reference numerals in FIG. 4 as in FIGS. 1-3.

Of particular note, the cross-sectional view of FIG. 4 readily depicts the motor bearing pocket 30 and the motor bearing 32, referenced above.

FIG. 5 is a schematic diagram depicting a perspective view of an exemplary piston assembly 80. Generally, the piston assembly 80 includes an integral piston and connecting rod. In an operable configuration, two such piston assemblies are provided, a first piston assembly being operable within the first cylinder 40, and a second piston assembly being configured oppositely to operate within the second cylinder 46 (see FIG. 1). The piston assemblies are connected to the motor via the motor shaft 20.

Referring to FIG. 5, the piston assembly 80 includes an integral piston 82 and connecting rod member 84. The connecting rod member of the integral assembly further includes a bearing receiving portion 86. A bearing 88 is disposed in the bearing receiving portion, and an eccentric 90 is disposed in an eccentric receiving portion 92 of the bearing 88. The eccentric includes an offset opening 94 configured to receive a motor shaft, such as the motor shaft 20 above.

The piston assembly also includes a piston cup 96 held against the piston by a retainer washer 98, which is secured by a fastener 100. With such configuration, exhaust air from a top of the washer is directed through a valve 102 and valve porting 104, and out of a bottom of the connecting rod. The integral piston and connecting rod thus is a one-piece assembly with assembled two-port valve for vacuum operation. This valve allows flow to be exhausted through the piston, into the pump housing 12, and out of the vent holes 34 in the housing as described with respect to FIG. 1-4. This configuration thus provides additional and enhanced cooling for the pump as compared to conventional configurations. In conventional configurations, the flow is essentially opposite, and the intake flow rather than the exhaust flow moves the valve, which provides less cooling effect.

FIG. 6 is a schematic diagram depicting a perspective view of an exemplary pump housing cover 110. The pump housing cover 110 is configured to cover the back portion 18 of the housing 12. The pump housing cover includes a cover portion 112 and an integral gasket 114. In exemplary embodiments, the gasket is over molded onto the cover portion. The over molded gasket allows for faster product assembly because the cover portion and gasket are not two separate pieces, which results in more production throughput and lower assembly costs. In contrast, in conventional gasket covers the cover is removable and must be installed as a separate piece, which is less efficient.

FIG. 7 is schematic diagram depicting an exploded view of an exemplary integral pumping chamber and head, which may be employed as the integral pumping chamber and heads 44 and 50 described above with respect to FIG. 1. As referenced above, the integral pump and chamber heads respectively are coupled to the cylinders 40 and 46 as seen in FIG. 1.

The integral pumping chamber and heads 44/50 each has a pumping chamber 115. Each integral pumping chamber and head also has inlet and outlet reed valves 116 (two such valves are present in this embodiment), and associated hardware fastened to the integral chamber and head using a cover plate 118 and gasket 120 for sealing the compression chamber in the integral pumping chamber, such as a wobble piston/swing piston/rocking piston pump. The integral chamber and head component, and the cover plate and gasket, seal the compression chamber. This configuration results in a reduced overall size and weight as compared to conventional configurations, which typically employ a separate head and chamber piece. The integral pumping chamber and head also includes ports 122 configured to be coupled to lines for air to come in and out.

In accordance with the above, an aspect of the invention is a pump housing. In exemplary embodiments, the pump housing includes a front portion and a back portion. The front portion includes an opening forming a motor bearing pocket for seating a motor bearing and through which a motor shaft extends towards the back portion, at least one vent hole radially outwardly spaced from the opening for cooling, and a protrusion extending outward from the front portion, wherein the protrusion is configured to locate a motor housing.

In an exemplary embodiment of the pump housing, the protrusion is a circular protrusion.

In an exemplary embodiment of the pump housing, the opening and the at least one vent hole are provided in the protrusion.

In an exemplary embodiment of the pump housing, the pump housing includes four vent holes that are circumferentially spaced about the opening.

In an exemplary embodiment of the pump housing, the front portion of the housing is configured as a motor endbell.

Another aspect of the invention is a pump/compressor. In exemplary embodiments, the pump/compressor includes a pump housing having a front portion and a back portion, and a motor configured to be coupled to the front portion of the pump housing. The front portion of the pump housing includes an opening forming a motor bearing pocket for seating a motor bearing and through which the motor shaft extends towards the back portion, at least one vent hole radially outwardly spaced from the opening for cooling, and a protrusion extending outward from the front portion, wherein the protrusion is configured to locate a motor housing of the motor.

In an exemplary embodiment of the pump/compressor, the front portion of the housing is configured as a motor endbell, and the motor does not include a separate front endbell.

In an exemplary embodiment of the pump/compressor, the motor includes a bearing seating by the opening in the pump housing.

In an exemplary embodiment of the pump/compressor, the motor includes a shaft that extends through the opening towards the back portion of the pump housing.

In an exemplary embodiment of the pump/compressor, the protrusion is a circular protrusion that locates the motor housing.

In an exemplary embodiment of the pump/compressor, the pump/compressor further includes a pump housing cover, wherein the pump housing cover includes an integral gasket.

In an exemplary embodiment of the pump/compressor, the integral gasket is over molded onto a cover portion of the pump housing cover.

In an exemplary embodiment of the pump/compressor, the pump/compressor further includes first and second cylinders and heads respectively coupled to a top and a bottom portion of the pump housing.

In an exemplary embodiment of the pump/compressor, the pump/compressor further includes first and second integral pumping chambers and heads respectively coupled to the first and second cylinders.

In an exemplary embodiment of the pump/compressor, each of the first and second integral pumping chambers and head includes a cover plate and gasket for sealing a compression chamber in the integral pumping chamber and head.

In an exemplary embodiment of the pump/compressor, further includes a piston assembly including an integral piston and connecting rod member operable within the pump/compressor.

In an exemplary embodiment of the pump/compressor, the piston assembly further includes a bearing receiving portion, a bearing disposed in the bearing receiving portion, and an eccentric disposed in an eccentric receiving portion of the bearing.

In an exemplary embodiment of the pump/compressor, the eccentric includes an offset opening configured to receive the motor shaft.

In an exemplary embodiment of the pump/compressor, the piston assembly further comprises a piston cup held against the piston by a retainer washer, wherein exhaust air from a top of the washer is directed through valve porting in the piston and out of a bottom of the connecting rod.

Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application. 

What is claimed is:
 1. A pump housing comprising: a front portion and a back portion, wherein the front portion comprises: an opening forming a motor bearing pocket for seating a motor bearing and through which a motor shaft extends towards the back portion; at least one vent hole radially outwardly spaced from the opening for cooling; and a protrusion extending outward from the front portion, wherein the protrusion is configured to locate a motor housing.
 2. A pump housing according to claim 1, wherein the protrusion is a circular protrusion.
 3. A pump housing according to claim 1, wherein the opening and the at least one vent hole are provided in the protrusion.
 4. A pump housing according to claim 1, wherein the pump housing includes four vent holes that are circumferentially spaced about the opening.
 5. A pump housing according to claim 1, wherein the front portion of the housing is configured as a motor endbell.
 6. A pump/compressor comprising: a pump housing comprising a front portion and a back portion; and a motor configured to be coupled to the front portion of the pump housing; wherein the front portion of the pump housing comprises: an opening forming a motor bearing pocket for seating a motor bearing and through which the motor shaft extends towards the back portion; at least one vent hole radially outwardly spaced from the opening for cooling; and a protrusion extending outward from the front portion, wherein the protrusion is configured to locate a motor housing of the motor.
 7. A pump/compressor according to claim 6, wherein the front portion of the housing is configured as a motor endbell, and the motor does not include a separate front endbell.
 8. A pump/compressor according to claim 6, wherein the motor includes a bearing seating by the opening in the pump housing.
 9. A pump/compressor according to claim 6, wherein the motor includes a shaft that extends through the opening towards the back portion of the pump housing.
 10. A pump/compressor according to claim 6, wherein the protrusion is a circular protrusion that locates the motor housing.
 11. A pump/compressor according to claim 6, further comprising a pump housing cover, wherein the pump housing cover includes an integral gasket.
 12. A pump/compressor according to claim 11, wherein the integral gasket is over molded onto a cover portion of the pump housing cover.
 13. A pump/compressor according to claim 6, further comprising first and second cylinders and heads respectively coupled to a top and a bottom portion of the pump housing.
 14. A pump/compressor according to claim 13, further comprising first and second integral pumping chambers and heads respectively coupled to the first and second cylinders.
 15. A pump/compressor according to claim 14, wherein each of the first and second integral pumping chambers and head includes a cover plate and gasket for sealing a compression chamber in the integral pumping chamber and head.
 16. A pump/compressor according to 6, further comprising a piston assembly including an integral piston and connecting rod member operable within the pump/compressor.
 17. A pump/compressor according to claim 16, wherein the piston assembly further comprises: a bearing receiving portion; a bearing disposed in the bearing receiving portion; and an eccentric disposed in an eccentric receiving portion of the bearing.
 18. A pump/compressor according to claim 17, wherein the eccentric includes an offset opening configured to receive the motor shaft.
 19. A pump/compressor according to claim 16, wherein the piston assembly further comprises a piston cup held against the piston by a retainer washer, wherein exhaust air from a top of the washer is directed through valve porting in the piston and out of a bottom of the connecting rod. 